Axle disconnect assembly with directional roller clutch

Abstract

An axle disconnect assembly comprises a shaft extending axially along a central axis, a universal joint including an outer drive member having a substantially annular axial flange extending axially outwardly from the outer drive member coaxially with the central axis so as to form an annular space between the axial flange and the shaft, and a directional roller clutch disposed in the annular space. The directional roller clutch is provided for selectively drivingly coupling the shaft to the outer drive member of the universal joint. The directional roller clutch includes a plurality of rolling elements provided between the outer and inner race members. The rolling elements of the directional roller clutch radially support the outer drive member of the universal joint for rotation about to the shaft.

1 . An axle disconnect assembly comprising:
 a shaft extending axially along a central axis;   a universal joint including an outer drive member and an inner drive member disposed substantially within said outer drive member, said outer drive member having a substantially annular flange extending axially from said outer drive member coaxially with said central axis so as to form an annular space between said axial flange and said shaft; and   a directional roller clutch disposed in said annular space, said directional roller clutch provided for selectively drivingly coupling said shaft to said outer drive member of said universal joint;   said directional roller clutch including a plurality of rolling elements provided between said outer and inner race members;   said rolling elements of said directional roller clutch radially supporting said outer drive member of said universal joint for rotation about to said shaft.   
     
     
         2 . The axle disconnect assembly as defined in  claim 1 , wherein said directional roller clutch further includes an outer race member having a circumferentially extending outer raceway surface located around said central axis and an inner race member having a circumferentially extending inner raceway surface located around said central axis;
 wherein said outer race member is mounted to an inner peripheral surface of said axial flange of said outer drive member of said universal joint and said inner race member is mounted to an outer peripheral surface of said shaft.   
     
     
         3 . The axle disconnect assembly as defined in  claim 2 , wherein one of said outer raceway surface and said inner raceway surface has a plurality of cam surfaces formed at equidistantly spaced apart locations which define a plurality of cam members; each of said cam surfaces defines a wedge-shaped space in a gap which is narrow on both sides thereof between said outer raceway surface and said inner raceway surface. 
     
     
         4 . The axle disconnect assembly as defined in  claim 1 , further including a thrust bearing axially supporting said outer drive member of said universal joint for rotation relative to said shaft. 
     
     
         5 . The axle disconnect assembly as defined in  claim 4 , wherein said thrust bearing is mounted to a distal end of said shaft within said outer drive member of said universal joint. 
     
     
         6 . The axle disconnect assembly as defined in  claim 1 , wherein said outer drive member has a substantially radially oriented end wall provided with a central opening therethrough so as to receive said distal end of said shaft through said central opening. 
     
     
         7 . The axle disconnect assembly as defined in  claim 1 , further comprising an electromagnetic actuator for selectively actuating said directional roller clutch; said actuator includes an electromagnet and an annular armature axially movable relative thereto. 
     
     
         8 . The axle disconnect assembly as defined in  claim 7 , wherein said armature is axially movable by said electromagnet between deactivated position in which said directional roller clutch is disengaged so that said shaft is disconnected from said universal joint, and an activated position in which said directional roller clutch is engaged so that said shaft is drivingly connected to said universal joint. 
     
     
         9 . The axle disconnect assembly as defined in  claim 7 , wherein said electromagnetic actuator further comprises a compression spring element biasing said armature away from said electromagnet. 
     
     
         10 . The axle disconnect assembly as defined in  claim 1 , wherein said universal joint is a constant velocity joint. 
     
     
         11 . An auxiliary drive axle assembly of an all-wheel-drive motor vehicle, said auxiliary drive axle assembly comprising:
 a differential assembly;   a first shaft extending axially outwardly from said differential assembly along a central axis thereof;   a first universal joint including an outer drive member and an inner drive member disposed substantially within said outer drive member, said outer drive member having a substantially annular flange extending axially from said outer drive member coaxially with said central axis so as to form an annular space between said axial flange and said first shaft; and   an axle disconnect assembly including a first directional roller clutch disposed in said annular space, said first directional roller clutch provided for selectively drivingly coupling said first shaft to said outer drive member of said first universal joint;   said first directional roller clutch including a plurality of rolling elements provided between said axial flange and said first shaft;   said rolling elements of said first directional roller clutch radially supporting said outer drive member of said first universal joint for rotation about said first shaft.   
     
     
         12 . The auxiliary drive axle assembly as defined in  claim 11 , wherein said first directional roller clutch further includes an outer race member having a circumferentially extending outer raceway surface located around said central axis and an inner race member having a circumferentially extending inner raceway surface located around said central axis;
 wherein said outer race member is mounted to an inner peripheral surface of said axial flange of said outer drive member of said first universal joint and said inner race member is mounted to an outer peripheral surface of said first shaft.   
     
     
         13 . The auxiliary drive axle assembly as defined in  claim 12 , wherein one of said outer raceway surface and said inner raceway surface has a plurality of cam surfaces formed at equidistantly spaced apart locations which define a plurality of cam members; each of said cam surfaces defines a wedge-shaped space in a gap which is narrow on both sides thereof between said outer raceway surface and said inner raceway surface. 
     
     
         14 . The auxiliary drive axle assembly as defined in  claim 11 , further including a thrust bearing axially supporting said outer drive member of said first universal joint for rotation relative to said first shaft. 
     
     
         15 . The auxiliary drive axle assembly as defined in  claim 14 , wherein said thrust bearing is mounted to a distal end of said first shaft within said outer drive member of said first universal joint. 
     
     
         16 . The auxiliary drive axle assembly as defined in  claim 11 , wherein said outer drive member has a substantially radially oriented end wall provided with a central opening therethrough so as to receive said distal end of said shaft through said central opening. 
     
     
         17 . The auxiliary drive axle assembly as defined in  claim 11 , wherein said first directional roller clutch further comprises an electromagnetic actuator for selectively actuating said first directional roller clutch; said electromagnetic actuator includes an electromagnet and an annular armature axially movable relative thereto. 
     
     
         18 . The auxiliary drive axle assembly as defined in  claim 17 , wherein said armature is axially movable by said electromagnet between deactivated position in which said first directional roller clutch is disengaged so that said first shaft is disconnected from said first universal joint, and an activated position in which said first directional roller clutch is engaged so that said first shaft is drivingly connected to said first universal joint. 
     
     
         19 . The auxiliary drive axle assembly as defined in  claim 17 , wherein said first electromagnetic actuator further comprises a compression spring element biasing said armature away from said electromagnet. 
     
     
         20 . The auxiliary drive axle assembly as defined in  claim 11 , wherein said first universal joint is a constant velocity joint. 
     
     
         21 . The auxiliary drive axle assembly as defined in  claim 11 , wherein said first directional roller clutch is a bi-directional clutch. 
     
     
         22 . The auxiliary drive axle assembly as defined in  claim 11 , further comprising:
 a second shaft extending axially outwardly from said differential assembly along said central axis thereof opposite to said first shaft; and   a second universal joint including an outer drive member and an inner drive member disposed substantially within said outer drive member, said outer drive member having a substantially annular axial flange extending axially outwardly from said outer drive member coaxially with said central axis so as to form an annular space between said axial flange and said second shaft;   said axle disconnect assembly further including a second directional roller clutch disposed in said annular space, said second directional roller clutch provided for selectively drivingly coupling said second shaft to said outer drive member of said second universal joint;   said second directional roller clutch including a plurality of rolling elements provided between said axial flange and said second shaft;   said rolling elements of said second directional roller clutch radially rotatably supporting said outer drive member of said second universal joint for rotation about said second shaft.   
     
     
         23 . The auxiliary drive axle assembly as defined in  claim 22 , wherein said second directional roller clutch is substantially similar to said first directional roller clutch.